Yamaha 650-701-760 Total Loss Ignition System

Yamaha 650-701-760Total Loss Ignition SystemPN 42380IMPORTANT: Read these instructions before attempting the installation!WARNING: During installation, disconnect the battery cables. When disconnecting thebattery, always remove the Negative cable first and install it last.Parts Included In This Kit1 1 - Trigger Plate, Yam: 650/701/760 PN 30-12-50151 - Grommet, Yam: 650/701/760 PN 30-12-50162 - 6mm x 20mm Button Head Stainless Bolts2 - 14 x 6.4mm Compression Washer1 - Spark Plug Wire Set PN 30-00-35051 - Flywheel PN 30-12-45102 - Trigger Pickup PN 30-00-40352 - Coils PN 30-00-30051 - Ignition PN 00-00-2530Parts Not Included But May Be Required1 - Starter Relay PN 00-00-05251 - Waterproof On/Off Switch PN 00-00-05161 - Momentary On/Off Switch PN 00-00-0520Tools Required1 - 4mm Allen Wrench1 - Phillips Screw Driver1 - 1/2” Drive Rachet1 - 1/2 x 17mm Socket1 - Torque Wrench1 - Wire Terminal Crimper1 - Heat GunMSD POWERSPORTSIgnition Mounting Plate:Yamaha Super Jet, Blaster, VXR, WaveRaider, WaveRunner, PN 30-06-05361 - Caliper or Measuring Device1 - Clay or Soft Wax1 - Flywheel Puller1 - Flywheel Holder WWW.MSDPOWERSPORTS.COM (915) 858-3365 FAX (915) 858-3496

2INSTALLATION INSTRUCTIONSMOUNTINGThe FDP Watercraft Ignition may be mounted in any location except on the engine or near theexhaust manifold. Excessive heat at these locations could damage the ignition.It is recommended that a mounting plate be fabricated out of aluminum or stainless steel andthe ignition, coil and starter relay be mounted to it. (Use the template supplied to assist you inmaking a mounting plate for your craft). When selecting a mounting location make sure thatthe ignition’s cable assembly will reach the battery and flywheel areas.To simplify installation, FDP offers mounting plates for the Yamaha (Figure 1). These strongaluminum plates are pre-drilled and attach to the factory mounting locations. Part numbersare listed on page 1.The following are suggested areas to install the mounting plate to your craft.Figure 1 An FDP Mounting Plate.Yamaha Blaster, SuperJet VXR/Wave-Runner, Raider 701/760Remove the stock electrical box and mount the plate to existing mounting bosses.IgnitionUsing the Ignition as a template, mark the location of the mount-ing holes on the mountingplate. Remove the ignition and drill a 1/4” hole at each marked location. Mount the ignitionusing 10-32 x 3/4” or 5mm x 16mm stainless steel bolts (not supplied).Ignition Coil - Not On PlateUsing the coil as a template, mark the location of the mounting holes. Remove the coil anddrill a 1/4” hole at each marked location. Mount the coil using 1/4” x 3/4” or 6mm x 20mmstainless steel bolts (not supplied).Note: Do Not mount the coils any closer than 12 inches from the Ignition unit.Starter RelayWhen installing the Watercraft Ignition System it may be necessary to remove the stock starterrelay and replace it with a Waterproof External Relay. Using the relay as a template mark thelocation of the mounting holes. Remove the relay and drill a 1/4” hole at each marked location.Mount the coil using 1/4” x 1/2” or 6mm x 12mm stainless steel bolts (not supplied).MSD POWERSPORTS WWW.MSDPOWERSPORTS.COM (915) 858-3365 FAX (915) 858-3496

INSTALLATION INSTRUCTIONS3FLYWHEEL AND TRIGGER PLATEREMOVALBefore installing the Flywheel and Trigger Pickup assembly,the stock magneto flywheel and stator plate must beremoved. Refer to your craft’s service manual for the properremoval procedure.TRIGGER PLATE ASSEMBLY1. Assemble the trigger plate and pick-up assembly asshown in Figure 2. Place the trigger plate assembly on theengine bosses (Figure 3). Screw the supplied bolts andcompression washers into the case and lightly tighten tohold the trigger plate in the center of the case’s mountingpads.2. Slide the Green trigger pickup wires through the grommet.Install the grommet with wires attached in thecase and secure in place using the stockmounting hardware. Place a small amount ofsilicone sealer around the wires where theyenter the grommet (Figure 4).Figure 3 Mounting the Trigger PlateAssembly.Figure 4 Installing Grommet.MSD POWERSPORTS WWW.MSDPOWERSPORTS.COM (915) 858-3365 FAX (915) 858-3496

4INSTALLATION INSTRUCTIONSanything else between the battery and REDwire. (i.e. Switches, Connectors, etc.)2. Connect the BLACK wire to the negative sideof the battery only.Connecting the Coils1. Connect the WHITE wire from the ignition tothe ORANGE wire from the coil.2. Connect the BROWN wire from the ignition tothe BLACK wire from Coil A.3. Connect the YELLOW wire from the Ignitionto the BLACK wire from Coil B.Note: The ORANGE wire from the Ignition isnot used.Figure 7 Installing Perma-Seal Connectors.MSD POWERSPORTS WWW.MSDPOWERSPORTS.COM (915) 858-3365 FAX (915) 858-3496

INSTALLATION INSTRUCTIONS5CHECKING THE AIR GAPIt is important to have the correct air gap between the pickup and the flywheel. Too much maynot trigger the ignition while too little may cause contact to the pickup.1. Position a small amount of clay on the top of the trigger pickup (Figure 5).2. Place the flywheel on the crankshaft and lightly tap with a rubber or wooden object to holdit in place.3. Remove the flywheel and measure the thickness of the clay. Refer to the chart (Figure 6)for the number of shims that will need to be placed under the trigger pickup to obtain thecorrect air gap between the trigger pickup and the magnet in the flywheel. The correct airgap is .050” to .094”.4. Insert the necessary shims under the trigger pickup. Make sure the trigger retaining boltsare the correct length for the number of shims being used and are tightened firmly.INSTALLING THE FLYWHEELHeating the flywheel in boiling water to evenly expand the flywheel material before it is installedis necessary in the following procedure. Be sure to wear adequate skin and eye protectionto prevent possible burning.Note: If the starter gear was removed during the installation of the trigger plate, install the gearnow.1. Place the flywheel in boiling water for five minutes to evenly heat the flywheel.2. Position the Woodruff Key on the crankshaft.3. After the flywheel is thoroughly heated, remove the flywheel from the water and install it ontothe crankshaft. With a flashlight, look into the Woodruff Key slot and make sure the key isstill in position. Install the flywheel retaining nut/bolt.4. Attach a flywheel holding tool (not supplied) and torque the flywheel retaining bolt/nut to:65 ft-lbs.WIRINGAll wires must be routed to the locations described, then cut to length and have Perma-Sealsolderless connectors installed as shown in Figure 7. Applying a small amount of heat to theconnector which seals the wire to terminal connection.CABLE IDENTIFICATIONFigure 8 shows a complete installation of the Watercraft Ignition System.Connecting The Power LeadsBefore connecting the power leads, clean all surfaces of dirt, paint and other foreign substanceswhere the power leads will be connected . If the power leads need to be lengthened, use 14gauge wire and solder all splices. Power leads may be shortened if necessary.1. Connect the RED wire to the supplied fuse holder then directly to the battery positive ( )post or to the starter solenoid where the cable from the battery ( ) is connected. Do Not putFigure 8 Wiring the FDP Watercraft Ignition System.MSD POWERSPORTS WWW.MSDPOWERSPORTS.COM (915) 858-3365 FAX (915) 858-3496

6INSTALLATION INSTRUCTIONSCONNECTING THE FACTORY STOP SWITCHTo retain use of the factory stop switch located on the handle bar, attach the two wires comingfrom the stop switch to the PINK wire from the Ignition (Figure 8) and ground.CONNECTING THE TRIGGER PICKUPS1. Connect the two GREEN Trigger Pickup (A) wires to the Ignition BROWN wires.2. Connect the two GREEN Trigger Pickup (B) wires to the Ignition YELLOW wires.CONNECTING THE IGNITION KILL LANYARD FEATURELandyard Switches are listed as Normally Open or Closed when the switch is not connected toanything and the Landyard is removed from the switch.Normally Open Lanyard SwitchConnect the Violet wire of the Ignition to one side ofthe N.O. Lanyard Switch and the other side to positivebattery (12 volts) (Figure 9).Normally Closed Lanyard Switch(See connecting the factory stop switch.)CONNECTING THE HOLESHOT FEATUREConnect the LT BLUE wire to one side of a normallyopen momentary switch and the other side of theswitch to the BLACK wire (Figure 10).CONNECTING A TACHOMETERThe tach signal from the Ignition is a 12 volt square wave signal so many types of tachometerscan be used with the Ignition. Some of the more commonly used tachometers are the Jetmeter,Water Strike Marine, Optak, J.R. Electronics, VDO, Faria, and Autometer. Connect the tachometertrigger wire to the Ignitions Gray wire as shown in Figure 8.MSD POWERSPORTS WWW.MSDPOWERSPORTS.COM (915) 858-3365 FAX (915) 858-3496

INSTALLATION INSTRUCTIONS7adjustment with the first dimple being TDC.SECTION V TIMING AND PROGRAMMINGThe Watercraft Ignitions innovative design allows you to static time the engine before the engine isstarted. Study the special features shown in Figure 11 beforeproceeding.Figure 11 How to Check Static TimingAt this point in the installation, the ignition, coil and starterrelay should be mounted and installed in the craft along withthe trigger plate assembly and flywheel. Now you are ready totime the engine before starting the engine.1. Locate Top-Dead-Center (TDC) by placing a dial indicatorin the front cylinder and rotating the crankshaft until thepiston reaches the highest point in the cylinder (Figure12). When TDC is found, place a mark on the engineFigure 12 Finding TDC.case so that it lines up with the TDC mark of the far lefttiming mark on the flywheel as shown in figure (Figure13).2. Remove the ignition backing plate. Position selector S4of switch 3 to “ON” in order to disable the ignition’s sparkand activate the built-in LED indicator. Turn the ignitionon/off switch to the ON position and place the sparkplugs with spark plug wires attached against ground.WARNING: Do not trigger the ignition without the sparkplugs grounded and the plug wires attached. Damageto the ignition coil may result.3. Slowly rotate the flywheel clockwise until the small LEDon the side of the ignition turns on. When the LED is on,this indicates that the magnet on the flywheel is enteringFigure 13 Marking TDC.over the trigger pickup and that the ignition will fire atthis point.Note: As the flywheel is rotated the timingm a r k s w i l l d e c r e a s e f r o m a h i g h n u m b e r t o a l o w n u m b e r.Each dimple on the flywheel represents 5 of timing5. To adjust the ignition’s max timing the trigger plate must be rotated counter-clockwise toadvance the timing or clockwise to retard the timing. To adjust the plate without removing theflywheel, locate the four trigger plate access holes in the flywheel (Figure 11). Rotate the flywheelback to TDC and then insert two 4mm allen wrenches into the holes that line up with the triggerplate hold down bolts. Loosen the bolts to allow the trigger plate to be rotated.MSD POWERSPORTS WWW.MSDPOWERSPORTS.COM (915) 858-3365 FAX (915) 858-3496